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Hydrochloric Acid Corrosion Of A Venturi Gas Scrubber In A Continuous Catalyst Regeneration (CCR) Platformer

Two of the most common acid gases produced by the refining industry are chloride compounds such as hydrogen chloride (HCl) and chlorine (Cl2). These compounds can react with water to form solutions of hypochlorous and hydrochloric acid.  Droplets that condense are often highly concentrated, and acid concentrations in excess of 10% can be expected.1 A common source of these gaseous compounds is the overhead exhaust/vent of regeneration tower within a Continuous Catalytic Reforming (CCR) unit. Chloride compounds in the regenerator vent gas are absorbed in 1 wt.% caustic (NaOH) by subsequent contact in a venturi scrubber (ejector), before venting chloride free gas to atmosphere through a wash tower.  

Product Number: 51322-17770-SG
Author: Yousif A. Al Rabie, Iyad Al-Buraiki
Publication Date: 2022
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A venturi gas scrubber (ejector) made of Nickel-Chromium-Molybdenum (Ni-Cr-Mo) alloy UNS N06200 located in a Continuous Catalyst Regeneration (CCR) unit. failed prematurely after 1.5 years in operation. The scrubber was used to neutralize hydrochloric acid (HCl) and chlorine present in the regeneration tower vent gas using caustic injection (1 wt.% NaOH). A metallurgical failure analysis investigation concluded that the scrubber had failed due to hydrochloric acid (HCl) corrosion. In general, many alloys are susceptible to HCl corrosion at different acid concentrations. Originally, the scrubber was made of alloy UNS N10665 but was changed to alloy UNS N06200after multiple failures. Recommendations are provided to prevent similar damage recurrence. 

A venturi gas scrubber (ejector) made of Nickel-Chromium-Molybdenum (Ni-Cr-Mo) alloy UNS N06200 located in a Continuous Catalyst Regeneration (CCR) unit. failed prematurely after 1.5 years in operation. The scrubber was used to neutralize hydrochloric acid (HCl) and chlorine present in the regeneration tower vent gas using caustic injection (1 wt.% NaOH). A metallurgical failure analysis investigation concluded that the scrubber had failed due to hydrochloric acid (HCl) corrosion. In general, many alloys are susceptible to HCl corrosion at different acid concentrations. Originally, the scrubber was made of alloy UNS N10665 but was changed to alloy UNS N06200after multiple failures. Recommendations are provided to prevent similar damage recurrence. 

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